Foil part vectorization for mobile large scale additive manufacturing using foil-based build materials

ABSTRACT

The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

INTRODUCTION

The present disclosure generally relates to methods and apparatuses foradditive manufacturing using foil-based build materials. Morespecifically, the disclosure relates to providing a layer of foil to abuild area.

BACKGROUND

Additive manufacturing (AM) or additive printing processes generallyinvolve the buildup of one or more materials to make a net or near netshape (NNS) object, in contrast to subtractive manufacturing methods.Though “additive manufacturing” is an industry standard term (ASTMF2792), AM encompasses various manufacturing and prototyping techniquesknown under a variety of names, including freeform fabrication, 3Dprinting, rapid prototyping/tooling, etc. AM techniques are capable offabricating complex components from a wide variety of materials.Generally, a freestanding object can be fabricated from a computer aideddesign (CAD) model. A particular type of AM process uses electromagneticradiation such as a laser beam, to melt or sinter a powdered material,creating a solid three-dimensional object.

An example of an apparatus for AM using a powdered build material isshown in FIG. 1. The apparatus 140 builds objects or portions ofobjects, for example, the object 152, in a layer-by-layer manner bysintering or melting a powder material (not shown) using an energy beam170 generated by a source 150, which can be, for example, a laser forproducing a laser beam, or a filament that emits electrons when acurrent flows through it. The powder to be melted by the energy beam issupplied by reservoir 156 and spread evenly over a powder bed 142 usinga recoater arm 146 travelling in direction 164 to maintain the powder ata level 148 and remove excess powder material extending above the powderlevel 148 to waste container 158. The energy beam 170 sinters or melts across sectional layer of the object being built under control of anirradiation emission directing device, such as a laser galvo scanner162. The galvo scanner 162 may comprise, for example, a plurality ofmovable mirrors or scanning lenses. The speed at which the energy beamis scanned is a critical controllable process parameter, impacting thequantity of energy delivered to a particular spot. Typical energy beamscan speeds are on the order of 10 to several thousand millimeters persecond. The build platform 144 is lowered and another layer of powder isspread over the powder bed and object being built, followed bysuccessive melting/sintering of the powder by the laser 150. The powderlayer is typically, for example, 10 to 100 microns in thickness. Theprocess is repeated until the object 152 is completely built up from themelted/sintered powder material. The energy beam 170 may be controlledby a computer system including a processor and a memory (not shown). Thecomputer system may determine a scan pattern for each layer and controlenergy beam 170 to irradiate the powder material according to the scanpattern. After fabrication of the object 152 is complete, variouspost-processing procedures may be applied to the object 152.Post-processing procedures include removal of excess powder by, forexample, blowing or vacuuming. Other post processing procedures includea stress relief heat treat process. Additionally, thermal and chemicalpost processing procedures can be used to finish the object 152.

Most commercial AM machines allow components to be built in alayer-by-layer manner using powdered build material, which has severaldrawbacks. Generally, loose powder materials may be selectivelydifficult to store and transport. There may also be health risksassociated with inhalation of loose powders. Additional equipment forisolating the powder environment and air filtration may be necessary toreduce these health risks. Moreover, in some situations, loose powdermay become flammable.

In view of the foregoing, non-powder-based methods and apparatuses aredesirable.

SUMMARY

The following presents a simplified summary of one or more aspects ofthe present disclosure in order to provide a basic understanding of suchaspects. This summary is not an extensive overview of all contemplatedaspects and is intended to neither identify key or critical elements ofall aspects nor delineate the scope of any or all aspects. Its purposeis to present some concepts of one or more aspects in a simplified formas a prelude to the more detailed description that is presented later.

In one aspect, the present disclosure is directed to an apparatus foradditive manufacturing of an object, the apparatus comprising: a buildplate having a build face; a build unit facing the build face, the buildunit comprising a foil delivery unit and a radiation emission directingdevice, the build unit coupled to a positioning system capable ofproviding independent movement of the build unit in at least threedimensions with respect to the build plate/face; wherein the build unitis configured to move foil from the foil delivery unit into contact withthe build plate, or an object thereon, so that the foil may beirradiated and incorporated into the object. In some aspects, theradiation emission directing device comprises an energy source. In someaspects, the build unit further comprises a galvo scanner. In someaspects, the energy source is a laser source. In some aspects, theenergy source is an electron beam source. In some aspects, the foildelivery unit is a foil dispenser capable of storing one or more rollsof foil and dispensing a length of foil from an active roll of foil. Insome aspects, the apparatus further comprises an excess collection roll.In some aspects, the foil delivery unit is a foil sheet dispensercapable of storing and dispensing foil sheets. In some aspects, theapparatus further comprises a discard bin. In some aspects, the buildunit further comprises a gasflow device configured to provide a laminargas flow substantially parallel to a face of the foil.

In another aspect, the present disclosure is directed to a methodcomprising: positioning a build unit with respect to a build platehaving a face; dispensing, by the build unit, a layer of metal foilfacing the face of the build plate; repositioning the build unit tobring the foil into contact with the face of the build plate or anobject thereon; melting selected areas of the respective layer of metalfoil to the working surface on the face of the build plate or theobject; and removing unmelted areas of the respective layer of metalfoil from the object. In some aspects, the melting selected areas of therespective layer of metal foil to the work surface comprises irradiatingthe selected areas with an energy beam from an energy source. In someaspects, the energy source is a laser source. In some aspects, theenergy source is an electron beam source. In some aspects, the energysource is modulated by a galvo scanner. In some aspects, the dispensingby the build unit a layer of metal foil comprises dispensing a length offoil from a continuous roll of metal foil to extend a sheet of metalfoil over the face of the build plate. In some aspects, the removingunmelted areas of the respective layer of metal foil comprises windingunmelted areas of the sheet of metal foil onto an excess collectionroll. In some aspects, the dispensing by the build unit a layer of metalfoil comprises dispensing a sheet of metal foil from a cartridge,wherein the cartridge is capable of storing a plurality of sheets ofmetal foil. In some aspects, the removing remaining portions of thelayer of metal foil comprises moving the sheet of metal foil from theobject. In some aspects, repositioning the build unit comprisespositioning a gasflow device proximate to a face of the foil, to providea laminar gas flow substantially parallel to the face of the foil.

In one aspect, the present disclosure is directed to an apparatuscomprising a build plate having two opposite faces; a pair of buildunits on opposite faces of the build plate, each build unit comprising afoil delivery unit and a radiation emission directing device, each buildunit coupled to a positioning system capable of providing independentmovement of the respective build unit in at least three dimensions. Insome aspects, the radiation emission directing device comprises anenergy source. In some aspects, the build unit further comprises a galvoscanner. In some aspects, the energy source is a laser source. In someaspects, the energy source is an electron beam source. In some aspects,the foil delivery unit is a foil sheet dispenser capable of storing anddispensing foil sheets. In some aspects, the apparatus further comprisesa discard bin. In some aspects, the foil delivery unit is a foildispenser capable of storing one or more rolls of foil and dispensing alength of foil from an active roll of foil. In some aspects, theapparatus further comprises an excess collection roll. In some aspects,the apparatus further comprises a controller configured to control thepair of build units to concurrently build a pair of correspondingobjects on the two opposite faces.

In another aspect, the present disclosure is directed to a methodcomprising: positioning a pair of build units with respect to a buildplate having two opposite faces, each face comprising a work surface;dispensing, by each of the build units, a respective layer of metal foilover the opposite faces of the build plate; melting selected areas ofthe respective layer of metal foil to the work surface on each face ofthe build plate; and removing unmelted areas of the respective layer ofmetal foil. In some aspects, the melting selected areas of therespective layer of metal foil to the work surface comprises irradiatingthe selected areas with an energy source. In some aspects, the energysource is a laser source. In some aspects, the energy source is anelectron beam source. In some aspects, the energy source is modulated bya galvo scanner. In some aspects, the dispensing by each of the buildunits a respective layer of metal foil comprises dispensing a sheet ofmetal foil from a cartridge, wherein the cartridge is capable of storinga plurality of sheets of metal foil. In some aspects, the removingunmelted areas of the respective layer of metal foil comprises movingthe sheet from the work surface to a discard bin. In some aspects, thedispensing by each of the build units a respective layer of metal foilcomprises dispensing a length of foil from a continuous roll of metalfoil to extend a sheet of metal foil over the face of the build plate.In some aspects, the removing unmelted areas of the respective layer ofmetal foil comprises winding unmelted areas of the sheet of metal foilonto an excess collection roll. In some aspects, the dispensing,melting, and removing are performed concurrently by each of the buildunits based on a control signal from a controller.

In another aspect, the present disclosure is directed to a method ofvectorization for foil-based build materials, comprising: receiving arepresentation of a layer to be formed by fusing one or more regions ofa foil sheet to a workpiece; determining that at least a first region ofthe one or more regions defines an unfused opening isolated from aremaining portion of the foil sheet; dividing the first region into atleast two scan areas, wherein a fragment of the unfused opening adjacenteach scan area is connected to the remaining portion; fusing a firstscan area of the at least two scan areas to the workpiece; moving thefoil sheet; and fusing a second scan area of the at least two scan areasto the workpiece. In some aspects, the method further comprisesdetermining that a second unfused opening isolated from the remainingportion of the foil sheet has an area less than a threshold; andablating the second opening. In some aspects, the ablating comprisesablating the second unfused portion when the foil sheet is not incontact with the workpiece. In some aspects, moving the foil sheetcomprises: separating the foil sheet from the workpiece; repositioningthe foil sheet relative to the workpiece; and bringing the foil sheetinto contact with the workpiece. In some aspects, an edge of the firstscan area contacts an edge of the second scan area. In some aspects, theworkpiece includes an empty space between the first scan area and thesecond scan area. In some aspects, the method further comprises:dividing a second region into at least a third scan area and a fourthscan area; repositioning at least one of the third scan area and thefourth scan area; fusing the third scan area to the workpiece; movingthe foil sheet; and fusing a fourth scan area of the at least two scanareas to the work piece adjacent the third scan area. In some aspects,dividing the second region comprises: determining that a surface area ofa portion of the second region is less than an area of the remainingportion exterior to the first region; and designating the portion of thesecond region as the third scan area, wherein repositioning at least oneof the third scan area and the fourth scan area comprises moving thethird scan area to the remaining portion exterior to the first region.In some aspects, dividing the second region comprises: determining thata width of a portion of the second region along an axis is less than athreshold; and designating the portion of the second region as the thirdscan area, wherein repositioning at least one of the third scan area andthe fourth scan area comprises moving the third scan area.

In another aspect, the present disclosure is directed to an apparatusfor forming an object using foil-based build materials, comprising: abuild plate having a build face; a foil delivery unit; a radiationemission directing device; and a controller configured to: receive arepresentation of a layer to be formed by fusing one or more regions ofa foil sheet to a workpiece; determine that at least a first region ofthe one or more regions defines an unfused opening isolated from aremaining portion of the foil sheet; dividing the first region into atleast two scan areas, wherein a fragment of the unfused opening adjacenteach scan area is connected to the remaining portion; control theradiation emission directing device to fuse a first scan area of the atleast two scan areas to the workpiece; control the foil delivery unit tomove the foil sheet; and control the radiation emission directing deviceto fuse a second scan area of the at least two scan areas to theworkpiece. In some aspects, the controller is configured to: determinethat a second unfused opening isolated from the remaining portion of thefoil sheet has an area less than a threshold; and ablate the secondunfused opening. In some aspects, the controller is configured to ablatethe second unfused portion when the foil sheet is not in contact withthe workpiece. In some aspects, the controller is configured to:separate the foil sheet from the workpiece; reposition the foil sheetrelative to the workpiece; and bring the foil sheet into contact withthe workpiece. In some aspects, an edge of the fused first scan areacontacts an edge of the fused second scan area. In some aspects, theworkpiece includes an empty space between the first scan area and thesecond scan area. In some aspects, the controller is configured to:divide a second region into at least a third scan area and a fourth scanarea; reposition at least one of the third scan area and the fourth scanarea; fuse the third scan area to the workpiece; move the foil sheet;and fuse a fourth scan area of the at least two scan areas to theworkpiece adjacent the third scan area. In some aspects, the controlleris configured to: determine that a surface area of a portion of thesecond region is less than an area of the remaining portion exterior tothe first region; and designate the portion of the second region as thethird scan area; and move the third scan area to the remaining portionexterior to the first region. In some aspects, the controller isconfigured to: determine that a width of a portion of the second regionalong an axis is less than a threshold; and designate the portion of thesecond region as the third scan area, wherein repositioning at least oneof the third scan area and the fourth scan area comprises moving thethird scan area. In some aspects, the apparatus further comprises apositioning system capable of providing independent movement of the foildelivery unit and the radiation emission directing device in at leastthree dimensions with respect to the build face.

In another aspect, the present disclosure is directed to an apparatusfor additive manufacturing of an object, the apparatus comprising: abuild plate having a build face; a build unit facing the build face, thebuild unit comprising: a foil delivery unit, and a radiation emissiondirecting device, wherein the build unit is configured to move foil fromthe foil delivery unit into contact with the build plate, or an objectthereon, so that the foil may be irradiated and incorporated into theobject; and one or more detectors configured to inspect one or more ofthe foil, the object, and radiation emitted or received by the radiationemission directing device. In some aspects, the apparatus furthercomprises a controller configured to receive data from the one or moredetectors and adjust one or more of radiation emitted by an energysource and/or the radiation emission directing device, the foil deliveryunit, the build unit, or the one or more detectors based on the receiveddata. In some aspects, the one or more detectors is located between thebuild plate and the foil delivery unit and is configured to inspect theobject. In some aspects, the one or more detectors comprises a thermalscanner configured to inspect the object and generate a thermal profileof the object. In some aspects, the one or more detectors comprises anelectromagnetic detector configured to apply an electric current to theobject and measure a magnetic property of eddy currents generated withinthe object. In some aspects, the one or more detectors comprises acomputerized tomography scanner. In some aspects, the one or moredetectors are configured to inspect before completion of the object. Insome aspects, the apparatus further comprises a foil collection deviceconfigured to receive a remaining portion of the foil after irradiation,wherein the one or more detectors configured to inspect the remainingportion.

In another aspect, the present disclosure is directed to a methodcomprising: positioning a build unit with respect to a build platehaving a face; dispensing, by the build unit, a layer of metal foilfacing the face of the build plate; repositioning the build unit tobring the foil into contact with the face of the build plate or anobject thereon; melting selected areas of the respective layer of metalfoil to the work surface on the face of the build plate or the object;removing remaining portions of the respective layer of metal foil fromthe object; and inspecting, by a detector, at least one of the layer ofmetal foil, the object, or the remaining portions of the respectivelayer of metal foil. In some aspects, the method includes at least onestep of inspecting, by a detector, the layer of metal foil before themelting or inspecting, by a detector, the object. In some aspects, themethod further comprises transmitting data on the layer of metal foilfrom the detector to a controller, comparing the data to a model for thefoil, and adjusting the foil according to the model. In some aspects,the method further comprises transmitting data on the object from thedetector to a controller, and comparing the data to a model for theobject. In some aspects, the method further comprises: determining thatthe data on the object differs from the model for the object by morethan a threshold amount; and stopping a build process for the object.

These and other aspects of the invention will become more fullyunderstood upon a review of the detailed description, which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example of an apparatus for AM according to conventionalmethods.

FIG. 2A shows a schematic diagram of an apparatus for AM according to afirst embodiment of the present disclosure.

FIG. 2B shows a schematic diagram of supplying a length of fresh buildmaterial according to a first embodiment of the present disclosure.

FIG. 2C shows a schematic diagram of cutting and irradiating a portionof build material in the preparation of a new layer according to a firstembodiment of the present disclosure.

FIG. 2D shows a schematic diagram of the apparatus after fusing of thenew layer to the object according to a first embodiment of the presentdisclosure.

FIG. 2E shows a schematic diagram of an apparatus for AM with processmonitoring according to a first embodiment of the present disclosure.

FIG. 3A shows a schematic diagram of an apparatus for AM according to asecond embodiment of the present disclosure.

FIG. 3B shows a schematic diagram of supplying a sheet of fresh buildmaterial according to a second embodiment of the present disclosure.

FIG. 3C shows a schematic diagram of cutting and irradiating a portionof build material in the preparation of a new layer according to asecond embodiment of the present disclosure.

FIG. 3D shows a schematic diagram of the apparatus after fusing of thenew layer to the object according to a second embodiment of the presentdisclosure.

FIG. 3E shows a schematic diagram of an apparatus for AM with processmonitoring according to a second embodiment of the present disclosure.

FIG. 4A shows a schematic diagram of an apparatus for AM according to athird embodiment of the present disclosure.

FIG. 4B shows a schematic diagram of supplying a length of fresh buildmaterial according to a third embodiment of the present disclosure.

FIG. 4C shows a schematic diagram of cutting and irradiating a portionof build material in the preparation of a new layer according to a thirdembodiment of the present disclosure.

FIG. 4D shows a schematic diagram of the apparatus after fusing of thenew layer to the object according to a third embodiment of the presentdisclosure.

FIG. 4E shows a schematic diagram of an apparatus for AM with processmonitoring according to a third embodiment of the present disclosure.

FIG. 5A shows a schematic diagram of an apparatus for AM according to afourth embodiment of the present disclosure.

FIG. 5B shows a schematic diagram of supplying a sheet of fresh buildmaterial according to a fourth embodiment of the present disclosure.

FIG. 5C shows a schematic diagram of cutting and irradiating a portionof build material in the preparation of a new layer according to afourth embodiment of the present disclosure.

FIG. 5D shows a schematic diagram of the apparatus after fusing of thenew layer to the object according to a fourth embodiment of the presentdisclosure.

FIG. 5E shows a schematic diagram of an apparatus for AM with processmonitoring according to a fourth embodiment of the present disclosure.

FIG. 6 shows a schematic diagram of an example layer to be added to anobject using any of the apparatuses of the present disclosure.

FIG. 7 shows a schematic diagram of the example layer of FIG. 7rearranged according to an aspect of the present disclosure.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appendeddrawings is intended as a description of various configurations and isnot intended to represent the only configurations in which the conceptsdescribed herein may be practiced. The detailed description includesspecific details for the purpose of providing a thorough understandingof various concepts. However, it will be apparent to those skilled inthe art that these concepts may be practiced without these specificdetails. In some instances, well known components are shown in blockdiagram form in order to avoid obscuring such concepts.

Mobile Large Scale Additive Manufacturing Using Foil-Based BuildMaterials

The present application is directed to methods and apparatuses formobile large scale additive manufacturing using foil-based buildmaterials. According to the present disclosure, additive manufacturingis carried out on a face of a build plate, using foil-based buildmaterials. Using a sheet of a thin “foil” metal placed above a region ofinterest allows the user to incident the opposite side of the foil witha radiation source and weld the foil immediately under the irradiationpoint to the surface below. Such technology creates a new layer of theobject from the foil in the same manner as a conventional powder bedprinter. However, the methods of the present disclosure have theadvantages of no powder handling, no recoat or recoat time, no recoaterjams, and gravitational decoupling, as the technology may be operated toprint at angles, upside down, or in zero gravity.

In some aspects, the method and apparatus of the present disclosure mayalso include process monitoring. With no powder bed, the growing part orobject may always be visible. This visibility allows for real-timeinspection including, but not limited to, surface finish inspection;dimensional tolerance examination, either via probe, laser ranger, orcamera; and microscopic metallurgical inspection. In some aspects,process monitoring may include post-inspection of the finished object orpart, of the most recently completed layer, of remaining portions of thefoil, or a combination of the foregoing. Process monitoring according tothe present disclosure may facilitate determination of part or objecthealth earlier than in powder bed-based additive manufacturing. Existingtechnologies and modalities for process monitoring, such as CT scanning,may be able to be used with the present disclosure, either in series orin parallel with the build process, or post-building.

Some such aspects may further include closed loop control, which canprovide the capability to perform layer-by-layer monitoring ofdeformation models and adjustment of the build process as unwantedgeometrical (or other) characteristics emerge. In addition to correctingobject characteristics, process monitoring and closed loop control mayalso facilitate monitoring the condition of additive manufacturingequipment. The visibility of the part during its build enables real-timefeedback and correction. In some aspects, a multi-sensor closed loopalgorithm may be used for modification of the scan progress. Improvedinspection capabilities may facilitate “on-the-fly” build compensationto obtain a more desirable end product (i.e., the object) with regardsto the product geometry or other properties.

As used herein, a “foil-based build material” is a continuous, uniform,solid, thin sheet of metal, conventionally prepared by hammering orrolling. In some aspects of the present disclosure, foil-based buildmaterials do not comprise a backing or carrier. Foils suitable for usewith the present disclosure may be used in the form of rolls of foil,which may or may not be pre-perforated, or in the form of pre-cut sheetsof foil. Foil-based build materials suitable for use with the presentdisclosure include, but are not limited to, aluminum, cobalt-chrome,HS188, maraging steel, stainless steels, tooling steel, nickel,titanium, copper, tin, cobalt, niobium, tantalum, gamma titaniumaluminide, Inconel 625, Inconel 718, Inconel 188, Haynes 188®, Haynes625®, Super Alloy Inconel 625™, Chronin® 625, Altemp® 625, Nickelvac®625, Nicrofer® 6020, Inconel 188, and any other material having materialproperties attractive for the formation of components using theabovementioned techniques.

As used herein, a material is “opaque” to radiation if the material doesnot transmit incoming radiation.

As used herein, to “modulate” an energy beam from an energy sourceincludes one or more of adjusting an angle of the beam, adjusting afocus of the beam, and translating a radiation emission directing devicein at least one dimension. Suitable radiation emission directing devicesfor use according to the present disclosure include, but are not limitedto, galvo scanners and deflecting coils. In some aspects, a radiationemission directing device may modulate an energy beam from an energysource by bending and/or reflecting the energy beam to scan differentregions on a build face and/or by xyz motion of the radiation emissiondirecting device, which may optionally be housed in a build unit.

As used herein, “radiation” refers to energy in the form of waves orparticles, including, but not limited to, heat, radio waves, visiblelight, x-rays, radioactivity, acoustic radiation, and gravitationalradiation.

FIGS. 2A-2D show schematic diagrams of an apparatus 240 according to afirst embodiment of the present disclosure.

Apparatus 240 comprises a build plate with a face 244, which isavailable for building an object by additive manufacturing (FIG. 2A). Insome aspects, the build plate and the face 244 lie in an xy-plane, withbuilding occurring in the z-direction relative to face 244. As usedherein, the term “above” may mean spaced apart in the z-direction. Itshould be appreciated that the apparatus 240 may not be confined to aparticular gravitational orientation. That is, although the z-directionextends vertically opposite a gravitational direction for theconventional apparatus 100, the apparatus 240 may operate with az-direction transverse to the gravitational direction, opposite thegravitation direction, or in zero gravity.

A build unit 275 comprising positioning system 275 a, 275 b for foildelivery unit 276 a, comprising foil supply 276 and foil collector 277,is used to build an object 252 using foil 278. In some aspects,positioning system 275 a, 275 b allows movement of foil delivery unit276 a in three dimensions. In some aspects, build unit 275 houses aradiation emission directing device, such as galvo scanner 262, whichmay be used to modulate energy beam 270 from energy source 250. Forexample, the galvo scanner 262 may reflect or bend the energy beam 270to scan different regions on the face 244 or an object thereon. In suchaspects, by moving to a particular location with respect to the face244, the build unit 275 may limit the angle θ₂ of energy beam 270 usedto scan the face 244. The limited angle may provide more consistentmelting of the foil. In other aspects, galvo scanner 262 is notcontained within build unit 275.

In some aspects, energy source 250 is a laser source. In other aspects,energy source 250 is an electron beam source. In such aspects, theapparatus 240 is operated under vacuum conditions. In some such aspects,the radiation emission directing device is a deflecting coil. The energysource 250 may be a laser source under either vacuum or non-vacuumconditions.

In some aspects, build unit 275 is attached to a positioning system,such as a gantry or a multidimensional coordinated head (for example, arobot arm), movable in at least three dimensions, which may be, e.g., x,y, and z coordinates, during operation, in order to position theradiation emission directing device (pictured as galvo scanner 262)and/or foil delivery unit 276 a relative to build plate face 244 and/orobject 252. In addition, build unit 275 is preferably rotatable in alldirections, with roll, pitch, and yaw. As a result, build unit 275 ispreferably able to operate upside down or at any angle.

In a first embodiment, foil delivery unit 276 a supplies a continuousroll of a build material in the form of a foil.

FIGS. 2B-2D represent steps of a method of additive manufacturingaccording to a first embodiment of the present disclosure. In someaspects, the foil delivery unit 276 a contains a foil supply roll 276and a collection roll 277. Supply roll 276 supplies a length of freshfoil 278, which extends over a build plate face 244, upon which object252 is built, in direction 282 towards collection roll 277 (FIGS.2A-2B).

In some aspects, supply roll 276 is supplied as a cartridge to beinstalled in the foil delivery unit. The cartridge may be a sealed unitthat protects the foil from external elements prior to insertion intothe apparatus 240. In such aspects, the cartridge may supply foilmanually or automatically after cartridge insertion. In such aspects,after all of the materials from the cartridge are expended, thecartridge can be removed or deposited off, and a fresh cartridge can beinserted (manually) or picked up (automatically), allowing the buildprocess to continue.

In some aspects, a laminar gas flow 281 is applied to the build area(FIG. 2C). Suitable gases for use in laminar gas flow include, but arenot limited to, nitrogen, argon, helium, and combinations thereof.Laminar flow may be effected by any suitable means known to those ofordinary skill in the art, such as by using a gasflow device 285, e.g.,as disclosed in U.S. patent application Ser. No. 15/406,454, withattorney docket no. 313524/037216.00060, filed Jan. 13, 2017, which isherein incorporated by reference in its entirety. In some aspects, thegasflow device 285 may be adapted to provide a reduced oxygenenvironment. During operation, if a laminar gas flow is used, then theenergy source 250 is a laser source and energy beam 270 is a laser beam.This facilitates removal of the effluent plume caused by laser melting.

When a layer of foil is irradiated, smoke, condensates, and otherimpurities flow into the laminar gasflow zone 281 and are transferredaway from the foil and the object being formed by the laminar gas flow.The smoke, condensates, and other impurities flow into the low-pressuregas outlet portion and are eventually collected in a filter, such as aHEPA filter. By maintaining laminar flow, the aforementioned smoke,condensates, and other impurities can be efficiently removed while alsorapidly cooling melt pool(s) created by the laser, without disturbingthe foil layer, resulting in higher quality parts with improvedmetallurgical characteristics. In an aspect, the gas flow in the gasflowvolume is at about 3 meters per second. The gas may flow in either the xor the y direction.

The oxygen content of the second controlled atmospheric environment, ifpresent, is generally approximately equal to the oxygen content of thefirst controlled atmospheric environment (the laminar gas flow zone281), although it does not have to be. The oxygen content of bothcontrolled atmospheric environments is preferably relatively low. Forexample, it may be 1% or less, or more preferably 0.5% or less, or stillmore preferably 0.1% or less. The non-oxygen gases may be any suitablegas for the process. For example, nitrogen obtained by separatingambient air may be a convenient option for some applications. Someapplications may use other gases such as helium, neon, or argon. Anadvantage of the present disclosure is that it is much easier tomaintain a low-oxygen environment in the relatively small volume of thefirst and second controlled atmospheric environments. It is preferablethat only relatively smaller volumes require such relatively tightatmospheric control, as disclosed in U.S. patent application Ser. No.15/406,454, with attorney docket no. 313524/037216.00060, filed Jan. 13,2017, which is herein incorporated by reference in its entirety.Therefore, according to the present disclosure, it is preferable thatthe first and second controlled atmospheric environments may be, forexample, 100 times smaller in terms of build volume than the buildenvironment. The first gas zone, and likewise the gasflow device 285,may have a largest xy cross-sectional area that is smaller than thesmallest xy cross-sectional area of the object 252. There is noparticular limit on the size of the object 252 relative to the first gaszone 281 and/or the gasflow device 285. Advantageously, the radiationemission directing device (illustrated, for example, as galvo scanner262) fires through the first and second gas zones, which are relativelylow oxygen zones. When the first gas zone is a laminar gas flow zone281, with substantially laminar gas flow, the energy beam 270 is a laserbeam with a more clear line of sight to the object, due to theaforementioned efficient removal of smoke, condensates, and othercontaminants or impurities.

In some aspects, the build unit comprises a gasflow device 285 adaptedto provide a substantially laminar gas flow to a laminar gas flow zone281 within two inches of, and substantially parallel to, a work surface,such as build plate 244 or an object 252 thereon. The gasflow device 285may be adapted to maintain a laminar gas flow zone 281, to provide a lowoxygen environment around the work surface in a region below the buildunit. There may also be a reduced oxygen gas zone above the laminar gasflow zone 281. In some aspects, both gas zones may be contained within acontainment zone surrounding at least the build unit and positioningsystem. In some aspects, the build unit may be at least partiallyenclosed to form a low oxygen environment above the build area of thework surface, i.e., around the path of the beam 270.

In the embodiment illustrated in FIG. 2B, the laminar gas flow zone 281is essentially the volume of gasflow device 285, i.e., the volumedefined by the vertical (xz) surfaces of pressurized inlet portion 283and pressurized outlet portion 284 and by extending imaginary surfacesfrom the respective upper and lower edges of the inlet portion to theupper and lower edges of the outlet portion of the xy plane.

In some aspects, laminar gas flow 281 is applied substantially parallelto the face of the length of fresh foil 278 not facing the object 252 orthe build plate face 244, giving rise to an active foil 280. Positioninggasflow device 285 and application of laminar gas flow 281 minimizes anydistance between active foil 280 and object 252 or, when building theinitial layer of the object 252, between active foil 280 and build plateface 244, thusly establishing contact between active foil 280 and object252 or, when building the initial layer of the object, between activefoil 280 and the build plate face 244. In some aspects, the apparatus240 may further comprise rollers to help establish contact betweenactive foil 280 and object 252 or, when building the initial layer ofthe object, between active foil 280 and build plate/face 244. Therollers may move in the z-direction with respect to the foil supply roll276 to bring the active foil 280 into contact with the object 252 or thebuild plate face 244, such as by forming bends 286, 287 in active foil280, and to retract the active foil 280 therefrom.

Energy beam 270 is then used to cut active foil 280 (FIG. 2C) in orderto produce an additional layer 258 (FIG. 2D). As used herein, “cutting”the active foil according to the present disclosure refers to detachingthe additional layer 258 (or the portion of foil 280 that will becomeadditional layer 258) from the bulk of active foil 280. The cutting ispreferably performed by the energy beam 270. In some aspects, layer 258may be the initial layer in the manufacture of object 252. In someaspects, layer 258 may be the final layer in the manufacture of object252. In some aspects, layer 258 may be an intermediate layer in themanufacture of object 252.

In some aspects, energy beam 270 first irradiates along a perimeter 254of the layer 258 to be added in order to fuse active foil 280 to object252 at perimeter 254 (FIG. 2C). In some aspects, the irradiationsimultaneously cuts through active foil 280. In other aspects, energybeam 270 cuts active foil 280 along perimeter 254 prior to irradiationwithin perimeter 254 to fuse the layer 258 to object 252. In otheraspects, energy beam 270 irradiates along perimeter 254 in order to fuseactive foil 280 to object 252 at perimeter 254, and then energy beam 270cuts active foil 280 along perimeter 254.

In some aspects, after cutting and irradiation (simultaneously orsequentially in either order) along perimeter 254, energy beam 270irradiates area 256 in a raster-fill manner, to fuse active foil 280 tothe object 252.

In other aspects, energy beam 270 first irradiates area 256 in araster-fill manner, to fuse active foil 280 to the object 252, and thencuts and irradiates along perimeter 254 of the layer added. In suchaspects, the cutting and irradiation along perimeter 254 may occursimultaneously or sequentially in either order.

Suitable settings for the energy beam 270, energy source 250, and/or theradiation emission directing device (illustrated as, e.g., galvo scanner262) for cutting active foil 280 and for irradiating active foil 280either along perimeter 254 or in area 256 are known or can be determinedby those of ordinary skill in the art.

Completion of cutting and irradiation along perimeter 254 creates a hole260, wherefrom new layer 258 was added to object 252, in remainingportion 279 (FIG. 2D). In some aspects, the laminar gas flow 281 may bereduced or eliminated upon creation of hole 260 and/or raster-filling ofarea 256, to enhance separation of remaining portion 279 from object252. Remaining portion 279 may then be advanced in direction 282 ontocollection roll 277, to provide a fresh length of foil 278 to build thenext layer. In some aspects, no further layers are built. In someaspects, one or more further layers are built.

In some aspects, apparatus 240 may further comprise one or moredetectors for process monitoring (FIG. 2E). The build process depictedin FIGS. 2B-2D reflects return radiation beam 289, which travels back tothe galvo scanner 262 and then to photodetector 288, which analyzesreturn radiation beam 289 for properties such as, but not limited to. Inaddition, apparatus 240 may further comprise detectors 290, 291 toinspect the foil and the object 252, respectively. Inspection bydetector 290 of the foil may include inspection of one or more of thefoil supply 276, collection roll 277, fresh foil 278, active foil 280,and remaining portion 279. Detector 291 may be located below a currentbuild layer. That is, at least once the object 252 reaches a thresholdsize in the z-dimension, the detector 291 extends in the z-dimensionless than the size of the object 252 in the z-dimension. This positionallows the detector 291 to directly observe the object 252 without thebuild unit 275 interfering in the observation. Additionally, such aperspective may not be available in a powder based apparatus becauseunfused powder would prevent direct observation of the object 252. Thedetector 291 may provide feedback regarding finished portions of theobject 252 before the entire object 252 has been completed. Detectors290, 291 may be each independently be any suitable detector, such as,but not limited to a camera or a thermal scanner. In an aspect, thedetector 291 may be an electromagnetic detector. The detector 291 mayapply an electric current to the object 252. The detector 291 mayobserve eddy currents within the object 252. The eddy currents mayindicate gaps or fractures within the object 252 that alter an expectedpattern. Accordingly, defects may be detected at an early stage of thebuild process.

In some aspects, detectors 288, 290, and 291 transmit data to acontroller, which may be a computer. In some aspects, the method mayinclude adjusting the build process in response to the data. Suitableadjustments can be determined by those of ordinary skill in the artbased on the data and on knowledge of the desired object 252 to bebuilt. Suitable adjustments may include, but are not limited to,adjusting one or more of the frequency or intensity of energy beam 270;repositioning one or more of the supply roll 276, excess collection roll277, gasflow device 285, build unit 275, and detectors 288, 290, or 291.Adjustments may be made by a controller, such as a computer, eitherautomatically or manually.

FIGS. 3A-D show schematic diagrams of an apparatus 340 according to asecond embodiment of the present disclosure. Apparatus 340 may besimilar in some aspects to apparatus 240.

Apparatus 340 comprises a build plate with a face 344, which isavailable for building an object by additive manufacturing (FIG. 3A). Insome aspects, the build plate and the face 344 lie in an xy-plane, withbuilding occurring in the z-direction relative to face 344. As usedherein, the term “above” may mean spaced apart in the z-direction. Itshould be appreciated that the apparatus 340 may not be confined to aparticular gravitational orientation. That is, although the z-directionextends vertically opposite a gravitational direction for the apparatus100, the apparatus 340 may operate with a z-direction transverse to theto the gravitational direction, opposite to the gravitational direction,or in zero gravity.

A build unit 375 comprising positioning system 375 a, 375 b for foildelivery unit 376 a, comprising foil supply 376 and foil collector 377,is used to build an object 352 using foil 378. In some aspects,positioning system 375 a, 375 b allows movement of foil delivery unit376 a in three dimensions. Build unit 375 may be similar in some aspectsto build unit 275. In some aspects, build unit 375 houses a radiationemission directing device, such as galvo scanner 362, which may be usedto modulate energy beam 370 from energy source 350. For example, galvoscanner 362 may reflect or bend the energy beam 370 to scan differentregions on the face 344 or an object thereon. In such aspects, by movingto a particular location with respect to face 344, the build unit 375may limit the angle θ₃ of energy beam 370 used to scan the face 344.This limited angle may provide more consistent melting of the foil. Inother aspects, galvo scanner 362 is not contained within build unit 375.

In some aspects, energy source 350 is a laser source. In other aspects,energy source 350 is an electron beam source. In such aspects, theapparatus 340 is operated under vacuum conditions. In some such aspects,the radiation emission directing device is a deflecting coil. The energysource 350 may be a laser source under either vacuum or non-vacuumconditions.

In some aspects, build unit 375 is attached to a positioning system,such as a gantry, movable in at least three dimensions, which may be,e.g., x, y, and z coordinates, during operation, in order to positionthe radiation emission directing device (illustrated as, e.g., galvoscanner 362) and/or foil delivery unit 376 a relative to build plateface 344 and/or object 352. In addition, build unit 375 is preferablyrotatable in at least two dimensions, i.e., in the xy-plane, about thez-axis.

In a second embodiment, foil delivery unit 376 a supplies pre-cut sheetsof foil.

FIGS. 3B-3D represent steps of a method of additive manufacturingaccording to a second embodiment of the present disclosure. In someaspects, the foil delivery unit 376 a contains a sheet cartridge 376 anda discard bin 377 (FIGS. 3A-3B). Discard bin 377 may be top-loading,bottom-loading, or side-loading, and may be covered or uncovered. Inother aspects, foil delivery unit 376 a contains a sheet cartridge 376and no discard bin. Sheet cartridge 376 supplies a fresh sheet of foil378, which extends over a build plate face 344, upon which object 352 isbuilt. The cartridge may be a sealed unit that protects the foil fromexternal elements prior to insertion in apparatus 340. FIG. 3B shows asimplified overhead view of a schematic of the apparatus 340 beforesheet cartridge 376 dispenses a sheet 378 of foil. In some aspects,sheet cartridge 376 stores multiple sheets 378 of foil. Sheet cartridges376 may supply each sheet 378 of foil manually or automatically aftercartridge insertion. After all of the materials from the cartridge 376are expended, the cartridge 376 can be removed or deposited off, and afresh cartridge can be inserted (manually) or picked up (automatically),allowing the build process to continue.

According to a second embodiment of the present disclosure, sheetcartridge 376 dispenses an active sheet 380 onto object 352 (not shown)or, in the case of building an initial layer of an object, onto buildplate face 344 (FIG. 3C).

In some aspects, a laminar gas flow (not shown) is applied to the faceof active sheet 380 not facing the object 352 or the build plate 344.Application of laminar gas flow may help minimize any distance betweenactive sheet 380 and object 352, thusly enhancing contact between activefoil 380 and object 352 or, when building the initial layer of theobject, between active foil 380 and the build plate face 344. Duringoperation, if a laminar gas flow is used, energy source 350 is a lasersource and energy beam 370 is a laser beam. Laminar gas flow accordingto the second embodiment of the present disclosure may be similar insome aspects to laminar gas flow according to the first embodiment ofthe present disclosure.

Energy beam 370 is then used to cut active foil 380 (FIG. 3C) in orderto produce a layer of object 352 (not shown). Cutting the active foilaccording to the second embodiment of the present disclosure may besimilar in some aspects to cutting the active foil according to thefirst embodiment of the present disclosure. In some aspects, the layermay be the initial layer in the manufacture of object 352. In someaspects the layer may be the final layer in the manufacture of object352. In some aspects, the layer may be an intermediate layer in themanufacture of object 352.

In some aspects, energy beam 370 first irradiates along a perimeter 354of the layer 358 to be added in order to fuse the active sheet 380 toobject 352 at perimeter 354 (FIG. 3C). In some aspects, the irradiationsimultaneously cuts through active foil 380. In other aspects, energybeam 370 cuts active foil 380 along perimeter 354 prior to irradiationalong perimeter 354 in order to fuse active foil 380 to object 352 atperimeter 354, and then energy beam 370 irradiates active sheet 380along perimeter 354.

In some aspects, after cutting and irradiation (simultaneously orsequentially in either order) along perimeter 354, energy beam 370irradiates area 356 in a raster-fill manner, to fuse active foil 380 tothe object 352.

In other aspects, energy beam 370 first irradiates area 356 in araster-fill manner, to fuse active foil 380 to the object 352, and thencuts and irradiates along perimeter 354 of the layer added. In suchaspects, the cutting and irradiation along perimeter 354 may occursimultaneously or sequentially in either order.

Suitable settings for the energy beam 370, energy source 350, and/or theradiation emission directing device (illustrated as, e.g., galvo scanner362) for cutting active foil 380 and for irradiating active foil 380along either perimeter 354 or in area 356 are known or can be determinedby those of ordinary skill in the art.

Completion of cutting and irradiation along perimeter 354 creates a hole360, wherefrom a new layer was added to object 352, in remaining portion379 (FIGS. 3C-3D). In some aspects, the laminar gas flow may be reducedor eliminated upon creation of hole 360 and/or raster-filling of area356, to enhance separation of remaining portion 379 from object 352.Remaining portion 379 may then be moved into discard bin 377, eithermanually or automatically, such as by the dispensing of a new activesheet 380 on top of object 352 to build the next layer. In some aspects,the apparatus 340 does not include a discard bin 377 and may comprise aseparate robotic arm for removing waste foil 379 from build plate face344. In other aspects, the apparatus 340 includes a discard bin 377 anda separate robotic arm for moving waste foil 379 into discard bin 377.

In some aspects, no further layers are built. In some aspects, one ormore further layers are built.

In some aspects, apparatus 240 may further comprise one or moredetectors for process monitoring (FIG. 3E). The build process depictedin FIGS. 3B-3D reflects return radiation beam 389, which may be similarin some aspects to return radiation beam 289 and travels back to galvoscanner 362 and then to photodetector 388. Photodetector 388 may besimilar in some aspects to photodetector 288. In addition, apparatus 340may further comprise detectors 390, 391, which may be similar in someaspects to detectors 290, 291, respectively. Inspection by detector 390of the foil may include inspection of one or more of sheet cartridge376, discard bin 377, foil sheet 380, and remaining portion 279.

Foil Part Warp Compensation for Mobile Large Scale AdditiveManufacturing Using Foil-Based Build Materials

In an aspect, the disclosure includes methods and apparatuses for warpcompensation during mobile large scale additive manufacturing usingfoil-based build materials. In conventional DMLM processes, heat appliedto one side of a build plate may result in warping of the build plate ora workpiece built thereon. According to the present disclosure, additivemanufacturing is carried out on opposite faces of a build plate,simultaneously, using foil-based build materials. Building on oppositefaces of a build plate simultaneously may minimize warping of the buildplate and/or the object or part being built by balancing heatdistribution on both sides of the build plate. In addition,simultaneously building on opposite faces of a build plate doubles thebuild rate per plate, thereby expediting manufacturing processes.

FIGS. 4A-4D show schematic diagrams of an apparatus according a thirdembodiment of the present disclosure.

Apparatus 440 comprises a build plate with two faces 444, 444′, both ofwhich are available for building an object by additive manufacturing(FIG. 4A). In some aspects, the build plate lies in an xy-plane withrespect to face 444 and in an x′y′-plane with respect to face 444′, withbuilding occurring in the z-direction relative to face 444 and in thez′-direction relative to face 444′. For simplicity, only building onface 444′ will be discussed, but it is to be understood that the sameaspects described for building on face 444′ apply to building on face444 with equal force.

As described above, additive manufacturing may be carried outsimultaneously on both build plate faces 444, 444′ of apparatus 440. Thetwo faces 444, 444′ are preferably symmetrical. Without wishing to bebound to any particular theory, it is believed that simultaneous,symmetrical additive manufacturing on faces 444, 444′ balances the heat,weight, and other factors and/or forces on each face and therebyminimizes warping of the object and/or the build plate.

In some aspects, identical objects 452, 452′ are constructed on faces444, 444′ respectively. In other aspects, objects 452, 452′ are notidentical. In some such aspects, objects 452, 452′ are complementary orsupplementary. In some aspects, the same build material is used on bothfaces 444, 444′. In other aspects, different build material are used tobuild on faces 444, 444′.

Building on faces 444, 444′ may be controlled by a controller 401. In anaspect where identical objects 452, 452′ are constructed, the controller401 receives a single input for the object 452, for example, acomputer-aided design (CAD) model of the object. The controller 401generates a control signal based on the object, for example, by slicingthe object to determine a scan pattern for each layer. The controlsignal is then sent to both sides of apparatus 440. Accordingly, therespective components (e.g., build units 475, 475′) are concurrentlycontrolled. At any point during the build process, the objects 452, 452′may substantially identical. Additionally, thermal properties andapplied forces of the two sides of apparatus 440 may be similar.Therefore, the apparatus 400 may double the build speed of apparatus 240and may potentially reduce warping due to thermal differentials andimbalanced forces.

A build unit 475′ comprising positioning system 475 a′, 475 b′ for foildelivery unit 476 a′, comprising foil supply 476′ and foil collector477′, is used to build an object 452′ using foil 478′. In some aspects,positioning system 475 a′, 475 b′ allows movement of foil delivery unit476 a′ in three dimensions. In some aspects, build unit 475′ houses aradiation emission directing device, such as galvo scanner 462′, whichmay be used to modulate energy beam 470′ from energy source 450′. Forexample, the galvo scanner 462′ may reflect or bend the energy beam 470′to scan different regions on the face 444′ or an object thereon. In suchaspects, by moving to a particular location with respect to face 444′,build unit 475′ may limit the angle θ₄′ of energy beam 470′ used to scanthe face 444′. The limited angle may provide more consistent melting ofthe foil. In other aspects, galvo scanner 462′ is not contained withinbuild unit 475′.

In some aspects, energy source 450′ is a laser source. In other aspects,energy source 450′ is an electron beam source. In such aspects, theapparatus 440 is operated under vacuum conditions. In some such aspects,the radiation emission directing device is a deflecting coil. The laserenergy source 450′ may be a laser source under either vacuum ornon-vacuum conditions.

In some aspects, build unit 475′ is attached to a positioning system,such as a gantry, movable in at least three dimensions, which may be,e.g., x, y, and z coordinates, during operation, in order to positionthe radiation emission directing device (illustrated as, e.g., galvoscanner 462′) and/or foil delivery unit 476 a′ relative to build plateface 444′ and/or object 452′. In addition, build unit 475′ is preferablyrotatable in all directions, with roll, pitch, and yaw. As a result,build unit 475′ is preferably able to operate upside down or at anyangle.

In a third embodiment, foil delivery unit 476 a′ supplies a continuousroll of a build material in the form of a foil. Foil delivery unit 476a′ may be similar in some aspects to foil delivery unit 276 a.

FIGS. 4B-4D represent steps of a method of additive manufacturingaccording to a third embodiment of the present disclosure. In someaspects, the foil delivery unit 476 a′ contains a foil supply roll 476′and a collection roll 477′. Supply roll 476′ supplies a length of freshfoil 478′, which extends over a build plate face 444′, upon which object452′ is built, in direction 482′ towards collection roll 477′ (FIGS.4A-4B).

In some aspects, supply roll 476′ is supplied as a cartridge to beinstalled in the foil delivery unit. The cartridge may be a sealed unitthat protects the foil from external elements prior to insertion intothe apparatus 440. In such aspects, the cartridge may supply foilmanually or automatically after cartridge insertion. In such aspects,after all of the materials from the cartridge are expended, thecartridge can be removed or deposited off, and a fresh cartridge can beinserted (manually) or picked up (automatically), allowing the buildprocess to continue.

In some aspects, a laminar gas flow 481′ is applied to the build area(FIG. 4C). Laminar gas flow 481′ may be similar in some aspects tolaminar gas flow 281. Suitable gases for use in laminar gas flow 281include, but are not limited to, nitrogen, argon, and/or helium, andcombinations thereof. Laminar flow may be effected by any suitable meansknown to those of ordinary skill in the art, such as by using a gasflowdevice 485′, e.g., as disclosed in U.S. patent application Ser. No.15/406,454, attorney docket no. 313524/037216.00060, filed Jan. 13,2017, which is herein incorporated by reference in its entirety. Gasflowdevice 485′ may be similar in some aspects to gasflow device 285. Insome aspects, the gasflow device 485′ may be adapted to provide areduced oxygen environment. During operation, if a laminar gas flow isused, then the energy source 450′ is a laser source and energy beam 470′is a laser beam.

In some aspects, the build unit comprises a gasflow device 485′ adaptedto provide a substantially laminar gas flow to a laminar gas flow zone481′ within two inches of, and substantially parallel to, a worksurface, such as build plate face 444′ or an object 452′ thereon. Thegasflow device 485′ may be adapted to maintain a laminar gas flow zone481′, to provide a low oxygen environment around the work surface in aregion below the build unit. There may also be a reduced oxygen zoneabove the laminar gas flow zone 481′. In some aspects, both gas zonesmay be contained within a containment zone surrounding at least thebuild unit and positioning system. In some aspects, the build unit maybe at least partially enclosed to form a low oxygen environment abovethe build area of the work surface, i.e., around the path of beam 470′;an example of such an at least partially enclosed build unit isdisclosed in U.S. patent application Ser. No. 15/406,454, which isherein incorporated by reference in its entirety.

In the embodiment illustrated in FIG. 4B, the laminar gas flow zone 481′is essentially the volume of gas flow device 485′, i.e., the volumedefined by the vertical (x′z′) surfaces of pressurized inlet portion483′ and pressurized outlet portion 484′ and by extending imaginarysurfaces from the respective upper and lower edges of the inlet portionto the upper and lower edges of the outlet portion in the x′y′ plane.

In some aspects, laminar gas flow 481′ is applied substantially parallelto the face of the length of fresh foil 478′ not facing the object 452′or the build plate face 444′, giving rise to an active foil 480′.Positioning of gasflow device 485′ and application of laminar gas flow481′ minimizes any distance between active foil 480′ and object 452′,thusly establishing contact between active foil 480′ and object 452′ or,when building the initial layer of the object, between active foil 480′and the build plate face 444′. When a laminar gas flow 481′ is used,energy source 450′ is a laser source and energy beam 470′ is a laserbeam. In some aspects, the apparatus 440 may further comprise rollers tohelp establish contact between active foil 480′ and object 452′ or, whenbuilding the initial layer of the object, between active foil 480′ andbuild face 444′. The rollers may move in the z′ direction with respectto the foil supply roll 476′ to bring active foil 480′ into contact withthe object 452′ or face 444′, such as by forming bends 486′, 487′ inactive foil 480′, and to retract the active foil 480′ therefrom.

Energy beam 470′ is then used to cut active foil 480′ (FIG. 4C) in orderto produce an additional layer 458′ (FIG. 4D). Cutting the active foilaccording to the third embodiment of the present disclosure may besimilar in some aspects to cutting the active foil according to thefirst embodiment. In some aspects, layer 458′ may be the initial layerin the manufacture of object 452′. In some aspects, layer 458′ may bethe final layer in the manufacture of object 452′. In some aspects,layer 458′ may be an intermediate layer in the manufacture of object452′.

In some aspects, energy beam 470′ first irradiates along a perimeter454′ of the layer 458′ to be added in order to fuse active foil 480′ toobject 452′ at perimeter 454′ (FIG. 4C). In some aspects, theirradiation simultaneously cuts through active foil 480′. In otheraspects, energy beam 470′ cuts active foil 480′ along perimeter 454′prior to irradiation along perimeter 454′ to fuse perimeter 454′ toobject 452′. In other aspects, energy beam 470′ irradiates alongperimeter 454′ in order to fuse active foil 480′ to object 452′ atperimeter 454′, and then energy beam 470′ cuts active foil 480′ alongperimeter 454′.

In some aspects, after cutting and irradiation (simultaneously orsequentially in either order) along perimeter 454′, energy beam 470′irradiates area 456′ in a raster-fill manner, to fuse active foil 480′to the object 452′.

In other aspects, energy beam 470′ first irradiates area 456′ in araster-fill manner, to fuse active foil 480′ to the object 452′, andthen cuts and irradiates along perimeter 454′ of the layer added. Insuch aspects, the cutting and irradiation along perimeter 454′ may occursimultaneously or sequentially in either order.

Suitable settings for the energy beam 470′, energy source 450′, and/orthe radiation emission directing device (illustrated as, e.g., galvoscanner 462′) for cutting active foil 480′ and for irradiating activefoil 480′ either along perimeter 454′ or in area 456′ are known or canbe determined by those of ordinary skill in the art.

Completion of cutting and irradiation along perimeter 454′ creates ahole 460′, wherefrom new layer 458′ was added to object 452′, inremaining portion 479′ (FIG. 4D). In some aspects, the laminar gas flow481′ may be reduced or eliminated upon creation of hole 460′ and/orraster-filling of area 456′, to enhance separation of remaining portion479′ from object 452′. Remaining portion 479′ may then be advanced indirection 482′ onto collection roll 477′, to provide a fresh length offoil 478′ to build the next layer. In some aspects, no further layersare built. In some aspects, one or more further layers are built.

In some aspects, apparatus 440 may further comprise one or moredetectors for process monitoring (FIG. 4E). The build process depictedin FIGS. 4B-4D reflects return radiation beam 489′, which may be similarin some aspects to return radiation beam 289 and travels back to galvoscanner 462′ and then to photodetector 488′. Photodetector 488′ may besimilar in some aspects to photodetector 288. In addition, apparatus 440may further comprise detectors 490′, 491′, which may be similar in someaspects to detectors 290, 291, respectively. Inspection by detector 490′of the foil may include inspection of one or more of foil supply roll476′, foil collection roll 477′, fresh foil 478′, active foil 480′, andremaining portion 479′. Detectors 491 and 491′ may be located onopposite sides of the build plate 444 and may be positioned to observethe respective objects 452 and 452′. The detector 491 may be located inthe z-direction less than a size of the object 452 in the z-direction.The detector 491′ may be located in the z-direction less than a size ofthe object 452′ in the z′-direction. As discussed above regarding thedetector 291, the positioning of a detector under the current buildlayer may allow direct observation of completed portions of the object452, 452′. As previously stated, it is to be understood that inspectionby detector 490 will be analogous (i.e., may include inspection of oneor more of foil supply roll 476, foil collection roll 477, etc.).

FIGS. 5A-D show schematic diagrams of an apparatus according to a fourthembodiment of the present disclosure.

Apparatus 540 comprises a build plate with two faces 544, 544′, both ofwhich are available for building an object by additive manufacturing(FIG. 5A). In some aspects, the build plate lies in an xy-plane withrespect to face 544 and in an x′y′-plane with respect to face 544′, withbuilding occurring in the z-direction relative to face 544 and in thez′-direction relative to face 544′ For simplicity, only building on face544′ will be discussed, but it is to be understood that the same aspectsdescribed for building on face 544′ apply to building on 544 with equalforce. Apparatus 540 and faces 544, 544′ are similar in some aspects toapparatus 440 and faces 444, 444′.

A build unit 575′ comprising positioning system 575 a′, 575 b′ for foildelivery unit 576 a′, comprising foil supply 576′ and foil collector577′, is used to build an object 552′ using foil 578′. In some aspects,positioning system 575 a′, 575 b′ allows movement of foil delivery unit576 a′ in three dimensions. Build unit 575′ may be similar in someaspects to build unit 475′. In some aspects, build unit 575′ houses aradiation emission directing device, such as galvo scanner 562′, whichmay be used to modulate energy beam 570′ from energy source 550′.Modulating energy beam 570′ may be similar in some aspects to modulatingenergy beam 470′. For example, galvo scanner 562′ may reflect or bendenergy beam 570′ from energy source 550′ to scan different regions onthe surface 544′ or an object 552′ thereon. In such aspects, by movingto a particular location with respect to face 544′, build unit 575′ maylimit the angle θ₅′ of energy beam 570′ used to scan the surface 544′This limited angle may provide more consistent melting of the foil. Inother aspects, galvo scanner 562′ is not contained within build unit575′.

In some aspects, energy source 550′ is a laser source. In other aspects,energy source 550′ is an electron beam source. In such aspects, theapparatus 540′ is operated under vacuum conditions. In some suchaspects, the radiation emission directing device is a deflecting coil.The energy source 550′ may be a laser source under either vacuum ornon-vacuum conditions.

In some aspects, build unit 575′ is attached to a positioning system,such as a gantry, movable in two to three dimensions, which may be,e.g., x, y, and z coordinates, during operation, in order to positionthe radiation emission directing device (illustrated as, e.g., galvoscanner 562′) and/or foil delivery unit 576 a′ relative to build plateface 544′ and/or object 552′. In addition, build unit 575′ is preferablyrotatable in at least two dimensions, i.e., in the x′y′-plane, aroundthe z′-axis.

In a fourth embodiment, foil delivery unit 576 a′ supplies pre-cutsheets of foil.

FIGS. 5B-5D represent steps of a method of additive manufacturingaccording to a fourth embodiment of the present disclosure. In someaspects, the foil delivery unit 576 a′ contains a sheet cartridge 576′and a discard bin 577′ (FIGS. 5A-5B). Sheet cartridge 576′ and discardbin 577′ may be similar in some aspects to sheet cartridge 376 anddiscard bin 377, respectively. Foil delivery unit 576 a′ may be similarin some aspects to foil delivery unit 376 a. Discard bin 577′ may betop-loading, bottom-loading, or side-loading, and may be covered oruncovered. In other aspects, foil delivery unit 576 a′ contains a sheetcartridge 576′ and no discard bin. Sheet cartridge 576′ supplies a freshsheet of foil 578′, which extends over a build plate face 544′, uponwhich object 552′ is built. FIG. 5B shows a simplified overhead view ofa schematic of the apparatus 540 before sheet cartridge 576′ dispenses asheet 578′ of foil. In some aspects, sheet cartridge 576′ storesmultiple sheets 578′ of foil. Sheet cartridges 576′ may supply eachsheet 578′ of foil manually or automatically after cartridge insertion.After all of the materials from the cartridge are expended, thecartridge 576′ can be removed or deposited off, and a fresh cartridgecan be inserted (manually) or picked up (automatically), allowing thebuild process to continue.

According to a fourth embodiment of the present disclosure, sheetcartridge 576′ dispenses an active sheet 580′ onto object 552′ (notshown) or, in the case of building an initial layer of an object, ontobuild plate face 544′ (FIG. 5C).

In some aspects, a laminar gas flow (not shown) is applied to the faceof active sheet 580′ not facing the object 552′ or the build plate 544′.Application of laminar gas flow may help minimize any distance betweenactive sheet 580′ and object 552′, thusly enhancing contact betweenactive foil 580′ and object 552′ or, when building the initial layer ofthe object, between active foil 580′ and the build plate face 544′.During operation, if a laminar gas flow is used, energy source 550′ is alaser source and energy beam 570′ is a laser beam. Laminar gas flowaccording to the fourth embodiment of the present disclosure may besimilar in some aspects to laminar flow according to the first, second,and third embodiments.

Energy beam 570′ is used to cut active foil 580′ (FIG. 5C) in order toproduce a layer of object 552′ (not shown). Cutting the active foilaccording to the fourth embodiment may be similar in some aspects tocutting according to the first, second, and third embodiments. In someaspects, the layer may be the initial layer in the manufacture of object552′. In some aspects the layer may be the final layer in themanufacture of object 552′. In some aspects, the layer may be anintermediate layer in the manufacture of object 552′.

In some aspects, energy beam 570′ first irradiates along a perimeter554′ of the layer 558′ to be added in order to fuse the active sheet580′ to object 552′ at perimeter 554′ (FIG. 5C). In some aspects, theirradiation simultaneously cuts through active foil 580′. In otheraspects, energy beam 570′ cuts active foil 580′ along perimeter 554′prior to irradiation along 554′ in order to fuse active foil 580′ toobject 552′ at perimeter 554′, and then energy beam 570′ cuts activesheet 580′ along perimeter 554′.

In some aspects, after cutting and irradiation (simultaneously orsequentially in either order) along perimeter 554′, energy beam 570′irradiates area 556′ in a raster-fill manner, to fuse active foil 580′to the object 552′.

In other aspects, energy beam 580′ first irradiates area 556′ in araster-fill manner, to fuse active foil 580′ to the object 552′, andthen cuts and irradiates along perimeter 554′ of the layer added. Insuch aspects, the cutting and irradiation along perimeter 554′ may occursimultaneously or sequentially in either order.

Suitable settings for the energy beam 570′, energy source 550′, and/orradiation emission directing device (illustrated as, e.g., galvo scanner562′) for cutting active foil 580′ and for irradiating active foil 580′along either perimeter 554′ or in area 556′ are known or can bedetermined by those of ordinary skill in the art.

Completion of cutting and irradiation along perimeter 554′ creates ahole 560′, wherefrom a new layer was added to object 552′, in remainingportion 579′ (FIGS. 5C-5D). In some aspects, the laminar gas flow may bereduced or eliminated upon creation of hole 560′ and/or raster-fillingof area 556′, to enhance separation of remaining portion 579′ fromobject 552′. Remaining portion 579′ may then be moved into discard bin577′, either manually or automatically, such as by the dispensing of anew active sheet 580′ on top of object 552′. In some aspects, theapparatus 540 does not include a discard bin 577′ and may comprise aseparate robotic arm for removing remaining portion 579′ from buildplate face 544′. In other aspects, the apparatus 540 includes a discardbin 577′ and a separate robotic arm for moving remaining portion 579′into discard bin 577′. In some aspects, no further layers are built. Insome aspects, one or more further layers are built.

In some aspects, apparatus 540 may further comprise one or moredetectors for process monitoring (FIG. 5E). The build process depictedin FIGS. 5B-5D reflects return radiation beam 589′, which may be similarin some aspects to return radiation beam 389 and travels back to galvoscanner 562′ and then to photodetector 588′. Photodetector 588′ may besimilar in some aspects to photodetector 388. In addition, apparatus 540may further comprise detectors 590′, 591′, which may be similar in someaspects to detectors 390, 391, respectively. Inspection by detector 590′of the foil may include inspection of one or more of sheet cartridge576′, discard bin 577′, foil sheet 578′, and remaining portion 579′. Aspreviously stated, it is to be understood that inspection by detector590 will be analogous (i.e., may include inspection of one or more ofsheet cartridge 576, discard bin 577, etc.).

FIG. 6 illustrates an example of a cross-sectional layer 600 of anobject (e.g., object 252) in an xy-plane. A controller 401 may slice theobject 252 into multiple such layers arranged in the z-dimension. Thenthe apparatus 240 builds the object 252 by scanning the layer x00 in thearea 256 of the active foil 280 to fuse the area 256 to the build plate244 of previously build portions of the object 252.

In the illustrated example, the layer 600 includes a main portion 610and side portions 620, 622. The main portion 610 includes a relativelylarge opening 612 and a relatively small opening 614. In a foil-basedapparatus such as the apparatus 240, an opening 612, 614 within a layer600 may pose a problem. When the layer 600 is scanned, an area definedby the perimeter 254 is detached from the active foil 280, which becomesthe remaining portion 279. When the entire area 256 is scanned, thedetached area becomes part of the object 252. When the layer 600includes an opening 612, 614, however, the foil within the openingbecomes detached from both the remaining portion 279 and the rest of thelayer 600. For some objects, the detached foil may be removed upon buildcompletion. However, it is also possible that the detached foilcorresponding to the opening 612 may move during a build operation andinterfere with the build operation. Additionally, for objects that forman enclosed hollow volume, the detached foil may become trapped withinthe object. The present disclosure provides techniques to avoid creationof detached foil portions.

In an aspect, a relatively small opening (e.g., opening 614) may beformed by ablating the foil. For example, the power of the energy source250 may be set to a level that causes the foil to disintegrate ratherthan fuse with an underlying object. In an aspect, the opening 614 maybe formed when the active foil 280 is not in contact with the object 252such that the ablation does not damage the object 252. In an aspect, thesize of an opening created by ablation is limited depending on the buildmaterial, shape of the opening, and power of the energy source 250.Accordingly, ablation may be used when the size and shape of the opening614 are less than threshold parameters.

FIG. 7 is a diagram showing the layer 600 of FIG. 6 rearranged as thelayer 700 without relatively large openings. The layer 700 can bescanned from the active foil 280 without creating detached foilcorresponding to the opening 612. The main portion 610 is divided into aleft portion 712 and a right portion 714 separated by a space 716. Thespace 716 connects to edge 720 of the active foil 280. The edges of theopening 612 are divided between the left portion 712 and right portion714. Accordingly, the foil within the opening is also connected to thespace 716. The side portion 620, 622 are also separated from leftportion 712 and a right portion 714 to reduce the total length of foilfor the layer. The relatively small opening 614 may remain within theright portion 714 and may be formed by ablation as discussed above.

When scanning the layer 700, the apparatus 240 moves the build unit 275and/or the active foil 280 in one or more dimensions relative to thebuild plate 244 and/or object 252. For example, the apparatus 240 firstscans the right portion 714 in a correct position relative to the buildplate 244 to add the right portion 714 to the object 252. The rightportion 714 may be cut from the active foil 280 by the scanning so thatthe active foil 280 may be moved relative to the right portion 714. Forexample, the apparatus 240 may move the active foil 280 in thez-dimension away from the right portion 714. The apparatus 240 thenadvances the active foil 280, or moves the build unit 275, in thex-dimension the distance y16 and also moves the build unit 275 in they-dimension to bring the left portion 712 into alignment with the rightportion 714. The build unit 275 may then move the active foil 280 in thez-dimension to restore contact between the active foil 280 and theobject 252. The build unit 275 then scans the left portion 712 to fusethe left portion 712 to the object 252. The apparatus 240 may follow asimilar sequence of positioning the build unit 275 and/or active foil280 to align the side portions 620, 622 in their respective locationsrelative to the main portion 610 formed by scanning left portion 712 andright portion 714.

Accordingly, multiple portions of a layer are sequentially scanned toform a complete layer of the object. Separating a layer of the objectinto the multiple portions prevents openings within the layer fromforming isolated detached foil sections. Additionally, separating thelayer into multiple portions may be used to rearrange portions of theobject on the foil to more efficiently utilize the area of the foil.Further, portions of sequential layers may overlap on the foil (e.g, inthe y-dimension) to provide further efficient use of foil.

While the present disclosure describes aspects of the invention using amobile build unit, various aspects may also be carried out using fixedbed foil-based materials. Aspects of additive manufacturing using fixedbed foil-based materials include those described in U.S. patentapplication Ser. No. ______, “Fixed Bed Large Scale AdditiveManufacturing Using Foil-Based Build Materials,” filed ______, withattorney docket no. 319267/0.37216.00135. the disclosure of which isincorporated herein by reference in its entirety.

This written description uses examples to disclose the invention,including the preferred embodiments, and also to enable any personskilled in the art to practice the invention, including making and usingany devices or systems and performing any incorporated methods. Thepatentable scope of the invention is defined by the claims, and mayinclude other examples that occur to those skilled in the art. Suchother examples are intended to be within the scope of the claims if theyhave structural elements that do not differ from the literal language ofthe claims, or if they include equivalent structural elements withinsubstantial differences from the literal language of the claims.Aspects from the various embodiments described, as well as other knownequivalents for each such aspect, can be mixed and matched by one ofordinary skill in the art to construct additional embodiments andtechniques in accordance with principles of this application.

1. A method of vectorization for foil-based build materials, comprising: receiving a representation of a layer to be formed by fusing one or more regions of a foil sheet to a workpiece; determining that at least a first region of the one or more regions defines an unfused opening isolated from a remaining portion of the foil sheet; dividing the first region into at least two scan areas, wherein a fragment of the unfused opening adjacent each scan area is connected to the remaining portion; fusing a first scan area of the at least two scan areas to the workpiece; moving the foil sheet; and fusing a second scan area of the at least two scan areas to the workpiece.
 2. The method of claim 1, further comprising: determining that a second unfused opening isolated from the remaining portion of the foil sheet has an area less than a threshold; and ablating the second unfused opening.
 3. The method of claim 2, wherein the ablating comprises ablating the second unfused portion when the foil sheet is not in contact with the workpiece.
 4. The method of claim 1, wherein moving the foil sheet comprises: separating the foil sheet from the workpiece; repositioning the foil sheet relative to the workpiece; and bringing the foil sheet into contact with the workpiece.
 5. The method of claim 1, wherein an edge of the first scan area contacts an edge of the second scan area.
 6. The method of claim 1, wherein the workpiece includes an empty space between the first scan area and the second scan area.
 7. The method of claim 1, further comprising: dividing a second region into at least a third scan area and a fourth scan area; repositioning at least one of the third scan area and the fourth scan area; fusing the third scan area to the workpiece; moving the foil sheet; and fusing a fourth scan area of the at least two scan areas to the workpiece adjacent the third scan area.
 8. The method of claim 7, wherein dividing the second region comprises: determining that a surface area of a portion of the second region is less than an area of the remaining portion exterior to the first region; and designating the portion of the second region as the third scan area, wherein repositioning at least one of the third scan area and the fourth scan area comprises moving the third scan area to the remaining portion exterior to the first region.
 9. The method of claim 7, wherein dividing the second region comprises: determining that a width of a portion of the second region along an axis is less than a threshold; and designating the portion of the second region as the third scan area, wherein repositioning at least one of the third scan area and the fourth scan area comprises moving the third scan area
 10. An apparatus for forming an object using foil-based build materials, comprising: a build plate having a build face; a foil delivery unit; a radiation emission directing device; and a controller configured to: receive a representation of a layer to be formed by fusing one or more regions of a foil sheet to a workpiece; determine that at least a first region of the one or more regions defines an unfused opening isolated from a remaining portion of the foil sheet; dividing the first region into at least two scan areas, wherein a fragment of the unfused opening adjacent each scan area is connected to the remaining portion; control the radiation emission directing device to fuse a first scan area of the at least two scan areas to the workpiece; control the foil delivery unit to move the foil sheet; and control the radiation emission directing device to fuse a second scan area of the at least two scan areas to the workpiece.
 11. The apparatus of claim 10, wherein the controller is configured to: determine that a second unfused opening isolated from the remaining portion of the foil sheet has an area less than a threshold; and ablate the second unfused opening.
 12. The apparatus of claim 11, wherein the controller is configured to ablate the second unfused portion when the foil sheet is not in contact with the workpiece.
 13. The apparatus of claim 10, wherein the controller is configured to: separate the foil sheet from the workpiece; reposition the foil sheet relative to the workpiece; and bring the foil sheet into contact with the workpiece.
 14. The apparatus of claim 10, wherein an edge of the fused first scan area contacts an edge of the fused second scan area.
 15. The apparatus of claim 10, wherein the workpiece includes an empty space between the first scan area and the second scan area.
 16. The apparatus of claim 10, wherein the controller is configured to: divide a second region into at least a third scan area and a fourth scan area; reposition at least one of the third scan area and the fourth scan area; fuse the third scan area to the workpiece; move the foil sheet; and fuse a fourth scan area of the at least two scan areas to the workpiece adjacent the third scan area.
 17. The apparatus of claim 16, wherein the controller is configured to: determine that a surface area of a portion of the second region is less than an area of the remaining portion exterior to the first region; and designate the portion of the second region as the third scan area; and move the third scan area to the remaining portion exterior to the first region.
 18. The apparatus of claim 16, wherein the controller is configured to: determine that a width of a portion of the second region along an axis is less than a threshold; and designate the portion of the second region as the third scan area, wherein repositioning at least one of the third scan area and the fourth scan area comprises moving the third scan area.
 19. The apparatus of claim 10, further comprising a positioning system capable of providing independent movement of the foil delivery unit and the radiation emission directing device in at least three dimensions with respect to the build face. 